Ford F150 Pickup. Manual — part 1593

19) KOER Output Water Soak Test Procedure For PCM Actuators
Start engine and allow to idle. Continue to monitor PIDs and/or circuits as in step 18). Go to area of
suspect wiring or component fault. While observing PID value, lightly spray water on suspect component,
circuit or connectors from component to PCM. A fault is indicated by a change in idle, or a sudden
change or mismatch in PID value. Also, compare actual values with HOT IDLE values in appropriate PIN
VOLTAGE/PID VALUE CHARTS article. If no fault is indicated, go to next step. If a fault is indicated,
isolate fault and repair as necessary. If wiring harness and connector(s) is okay, replace suspect
component.

20) Check For Intermittent Mechanical Concerns
If not done previously, inspect mechanical systems relating to DTC or symptom. Check the following:

z

Check if engine rocks during acceleration. If excessive movement is detected, check motor mounts.

z

Check for excessive component movement while driving vehicle during conditions that would
cause vibrations (high RPM, rough roads, etc.).

z

Check accelerator and transmission linkages for contact or interference.

If any concerns are detected, repair as necessary. If no concerns are detected, fault cannot be identified at
this time. Check for related Technical Service Bulletins (TSBs) for additional help. Testing is complete.

50) Intermittent Ignition Test Procedure
Check sensor shield connector. Ensure all accessories are off and battery is fully charged. Perform

QUICK TEST

. If any DTCs are present, service DTCs as necessary before continuing with this test. If

no DTCs are present, connect Rotunda Distributorless Ignition System Tester (DIST) (007-00075) and go
to next step.

51) Install Distributorless Ignition System Tester

Turn ignition switch to OFF position. Ensure all accessories are off. Install correct overlay and
appropriate program cartridge into DIST. Connect proper harness adapter to DIST 104-Pin PCM Adapter
(007-00110). Set rotary knob to position "1". Ensure WIGGLE TEST switch is off. On 4-cylinder
engines, set System Type switch to NON DUAL PLUG position.

and/or harnesses.

NOTE:

An intermittent mechanical concern can cause a good PCM system to
react abnormally.

NOTE:

A break in step numbering sequence occurs at this point. Procedure skips
from step 20) to step 50). No test procedures have been omitted.

NOTE:

The following step is for vehicles equipped with coil pack ignition system
(except Focus 2.0L). Testing must be performed using Rotunda
Distributorless Ignition System Tester (DIST) (007-00075). DIST cannot be
used on Focus 2.0L.

2003 Ford Pickup F150

2003 ENGINE PERFORMANCE Self-Diagnostics - CNG, Flex-Fuel & Gasoline

On all models, Disconnect PCM connector(s). Connect tester to PCM harness connector. Turn ignition
switch to ON position. Press RESET button on tester. Tester will perform self-test and all test LEDs will
light and a beep will be heard. If CASE GND (CKP SHIELD) FAULT MEMORY LED (EI only) stays
on, connect a jumper wire between PCM case to chassis ground and continue with test. If tester does not
perform KOEO self-test or VPWR LED does not turn on, refer to DIST warranty information. If DIST
performs KOEO self-test and VPWR LED is on, go to step 223).

223) Recreate Concern

With DIST connected to vehicle, attempt to duplicate fault by road testing vehicle. If vehicle is a no-start,
crank engine for 5-10 seconds. If FAULT MEMORY LEDs are off with engine running or during engine
cranking, attempt to recreate fault with FREEZE FRAME DATA or information from customer, then go
to step 234). If any FAULT MEMORY LED is on, go to step 234).

234) Wiggle Test Mode

Set DIST WIGGLE TEST switch to ON position. Set MODE switch to "A" position. Press RESET
button. Wait for WIGGLE TEST ACTIVE LED to come on. Lightly tap on components and wiggle and
bend wiring harness and connectors. Repeat test with MODE switch in "B" and "C" position. If FAULT
MEMORY LEDs are off, replace PCM. If any FAULT MEMORY LED is on, press RESET button and
wait for WIGGLE TEST ACTIVE LED to come on. Continue to test until intermittent fault is located.
Repair as necessary and retest.

NOTE:

WIGGLE TEST can only be used during Key On Engine Off (KOEO) Self-
Test. WIGGLE TEST monitors circuits for intermittent faults and has 3
different modes (A, B and C). MODE A checks for shorts to B+ or VPWR,
MODE B checks for open circuits, and MODE C checks for shorts to
ground. Attempt to duplicate fault conditions by wiggling wiring harness
and tapping on connectors and components. DIST will beep and turn on
appropriate LED for circuit where fault is detected.

NOTE:

A break in step numbering sequence occurs at this point. Procedure skips
from step 51) to step 223). No test procedures have been omitted.

NOTE:

A break in step numbering sequence occurs at this point. Procedure skips
from step 223) to step 234). No test procedures have been omitted.

2003 Ford Pickup F150

2003 ENGINE PERFORMANCE Self-Diagnostics - CNG, Flex-Fuel & Gasoline

EVAPORATIVE EMISSIONS DIAGNOSTIC TROUBLE CODE DEFINITIONS

EVAPORATIVE EMISSIONS DIAGNOSTIC TROUBLE CODE DEFINITIONS

DTC

Description

Go To Test

P0442

Small Leak Detected In EVAP System

A

P0455

Major Leak Or No Flow Detected In EVAP System

B

P0456

Very Small Leak Detected In EVAP System

A

P0457

Loose Or Missing Fuel Filler Cap

A

P1443

Very Small Or No Purge Flow Detected In EVAP System

B

P1450

Excessive Vacuum Detected In Fuel Tank

C

2003 Ford Pickup F150

2003 ENGINE PERFORMANCE Self-Diagnostics - CNG, Flex-Fuel & Gasoline

2003 Ford Pickup F150

2003 ENGINE PERFORMANCE Self-Diagnostics - CNG, Flex-Fuel & Gasoline

SYSTEM TESTS (EVAPORATIVE EMISSION)

Perform these tests when instructed during QUICK TEST or if directed here from another article or from
DIAGNOSTIC TROUBLE CODE DEFINITIONS. Perform appropriate evaporative emission system test.
See EVAPORATIVE EMISSIONS DIAGNOSTIC TROUBLE CODE DEFINITIONS. For emission-
related symptom tests, see EXCESSIVE FUEL ODOR , HISSING SOUND WHEN REMOVING FUEL
CAP or UNABLE TO REFUEL VEHICLE under EVAPORATIVE EMISSION SYSTEM TESTS in
SYSTEM & COMPONENT TESTING - GASOLINE article.

CANISTER VENT SOLENOID CLOSING PROCEDURE

Connect scan tool to Data Link Connector (DLC) and select OUTPUT TEST MODE under ADDITIONAL
SYSTEM FUNCTIONS. Turn ignition switch to ON position. Select FTP and FTP V PID from PID/DATA
MONITOR & RECORD menu. Select ALL OFF mode. Close canister vent solenoid by pressing START button
on scan tool.

EVAPORATIVE EMISSIONS SYSTEM LEAK TEST

Connect Evaporative Emissions System Leak Tester (134-00056) to EVAP test port. Close canister vent
solenoid. See CANISTER VENT SOLENOID CLOSING PROCEDURE. Pressurize EVAP system to 14 in.
H2O (3.48 kPa). Monitor system pressure for 2 minutes. EVAP system pressure should not fall below 8 in.
H2O (2 kPa). Repair leaks as necessary. Repeat EVAP system leak test until system pressure remains more than
8 in. H2O (2 kPa) after 2 minutes.

EVAPORATIVE EMISSION REPAIR VERIFICATION DRIVE CYCLE

Drive Cycle Recommendations

NOTE:

Prior to performing any system test, see HOW TO USE SYSTEM TESTS under
SYSTEM TESTS. If instructed to replace Powertrain Control Module (PCM) after
performing a system test, new PCM must be programmed. See PROGRAMMING
PCM.

NOTE:

To identify EVAP system components, see appropriate illustration. See Fig. 259-
Fig. 266 .

NOTE:

The following procedure is designed to execute and complete EVAPORATIVE
EMISSION REPAIR VERIFICATION DRIVE CYCLE and to clear DTC P1000,
inspection and maintenance (I/M) readiness code. When ambient air
temperature is less than 40°F (4.4°C), or more than 100°F (37.8°C), or altitude is
above 8000 feet, EVAP monitor will not run. If DTC P1000 must be cleared in
these conditions, PCM must detect them once (twice on some applications)
before EVAP monitor can be by-passed and DTC P1000 cleared. EVAP by-
passing procedure is described in the following drive cycle.

2003 Ford Pickup F150

2003 ENGINE PERFORMANCE Self-Diagnostics - CNG, Flex-Fuel & Gasoline

2003 Ford Pickup F150

2003 ENGINE PERFORMANCE Self-Diagnostics - CNG, Flex-Fuel & Gasoline